Fagor 800T Manual

7/28/2019 Fagor 800T Manual

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FAGOR 800T CNCINSTALLATION

MANUAL

Ref. 9707 (in)


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ABOUT THE INFORMATION IN THIS MANUAL

This manual is addressed to the machine manufacturer.

It includes the necessary information for new users as well as advanced subjects for thosewho are already familiar with the 800T CNC product.

It may not be necessary to read this whole manual. Consult the list of "New Features andModifications" and the appendix related to the machine parameters. Practically all of themare cross-referenced indicating the chapter and section of the manual where they are described.

This manual explains all the functions of the 800T CNC family. Consult the ComparisonTable for the models in order to find the specific ones offered by your CNC.

To install the CNC onto your machine, we suggest that you consult the appendix regarding

the enclosures required to mount the CNC as well as chapter 1 (CNC configuration) whichindicates the CNC dimensions and details the pin-out of its connectors.

Chapter 2 (Power and machine interface) shows how to connect the CNC to power A.C.(Mains) and to the electrical cabinet.

Chapter 3 "Auxiliary Functions" shows how to access special operating modes.

To adapt the CNC to the machine, set the CNC machine parameters. We suggest that youconsult chapters 4, 5, 6 and the appendices related to the machine parameters listed innumerical order.

Both appendices offer cross references indicating the section of the manual describing eachparameter.

When explaining each parameter in detail, chapters 4, 5 and 6, they sometimes refer tochapter 7 (concepts) where some of them are dealt with in further detail indicating how toperform various adjustments of the CNC-machine interface.

Once all machine parameters are set, we suggest that you write their settings down on thecharts provided for this purpose in the appendix on "Machine Parameter Setting Chart".

There is also an appendix on error codes which indicates some of the probable reasonswhich could cause each one of them.

Notes: The information described in this manual may be subject to variations due totechnical modifications.

FAGOR AUTOMATION, S.Coop. Ltda. reserves the right to modify the contentsof the manual without prior notice.


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Section Page

INDEX

Comparison Table for Fagor 800T CNC models ........................................... ix

New Features and modifications .................................................................... xiii

INTRODUCTION

Declaration of Conformity ............................................................................. 3

Safety Conditions ........................................................................................... 4Warranty Terms .............................................................................................. 7

Material Returning Terms .............................................................................. 8

Additional Remarks ........................................................................................ 9

Fagor Documentation for the 800T CNC....................................................... 11

Manual Contents ............................................................................................ 12

Chapter 1. 800T CNC CONFIGURATION

1.1 Introduction .................................................................................................... 1

1.2 Compact 800T CNC ....................................................................................... 1

1.2.1 Dimensions & Installation of the Compact 800T CNC ................................. 2

1.3 Modular 800T CNC........................................................................................ 3

1.3.1 Central Unit of the modular 800T CNC ........................................................ 4

1.3.2 Monitor of the modular 800T CNC ............................................................... 5

1.3.2.1 Monitor enclosure .......................................................................................... 7

1.3.2.2 Monitor-Central Unit connection connector ................................................. 8

1.3.3 Keyboard of the modular 800T CNC............................................................. 9

1.3.3.1 Keyboard-Central Unit connection connector ............................................... 10

1.4 Connectors and connections of the 800T CNC system................................. 12

1.4.1 Connectors A1, A3, A4 .................................................................................. 14

1.4.4.1 Dip-switches for connectors A1, A3, A4 ........................................................ 15

1.4.2 Connector A5 ................................................................................................. 16

1.4.2.1 Dip-switches for connector A5 ....................................................................... 17

1.4.3 Connector A6 ................................................................................................. 181.4.4 RS232C connector.......................................................................................... 19

1.4.5 Connector I/O 1 .............................................................................................. 22

1.4.5.1 Logic inputs of connector I/O 1..................................................................... 23

1.4.5.2 Logic outputs of connector I/O 1 .................................................................. 25

1.4.6 Connector I/O 2 .............................................................................................. 27

1.4.6.1 Logic outputs of connector I/O 2 .................................................................. 28


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Section Page

Chapter 2. POWER AND MACHINE INTERFACE

2.1 Power interface ............................................................................................... 1

2.1.1 Internal power supply..................................................................................... 1

2.2 Machine interface ........................................................................................... 22.2.1 General considerations ................................................................................... 2

2.2.2 Digital outputs ............................................................................................... 4

2.2.3 Digital inputs ................................................................................................. 4

2.2.4 Analog outputs ............................................................................................... 5

2.2.5 Feedback inputs.............................................................................................. 5

2.3 Set-up.............................................................................................................. 6

2.3.1 General considerations ................................................................................... 6

2.3.2 Precautions ..................................................................................................... 6

2.3.3 Connection ..................................................................................................... 7

2.3.4 System I/O test ............................................................................................... 8

2.4 Emergency input/output connection ............................................................. 10

2.5 Activation / deactivation of external devices ............................................... 12

Chapter 3. AUXILIARY FUNCTIONS

3.1 Millimeters inches.................................................................................... 1

3.2 Radius diameter ....................................................................................... 2

3.3 F mm(inches)/min mm(inches)/rev........................................................... 2

3.4 Tool ................................................................................................................ 3

3.4.1 Tool table ....................................................................................................... 3

3.4.1.1 Modification of tool dimensions ................................................................... 6

3.4.2 Tool calibration.............................................................................................. 7

3.4.3 Tool inspection .............................................................................................. 8

3.5 Cycle finishing pass and safety distance ....................................................... 9

3.6 Other automatic operations ............................................................................ 10

3.7 Auxiliary modes ............................................................................................. 11

3.8 Special modes ................................................................................................. 11

3.8.1 Test ................................................................................................................. 12

3.8.2 General parameters ......................................................................................... 15

3.8.3 Decoded "M" functions .................................................................................. 16

3.8.3.1 "M" functions sent out in BCD...................................................................... 18

3.8.4 Leadscrew error compensation ....................................................................... 19

3.9 Peripherals ...................................................................................................... 21

3.9.1 Peripheral mode .............................................................................................. 21

3.9.2 DNC communications .................................................................................... 22

3.10 Lock/unlock ................................................................................................... 233.11 Execution / Simulation of program P99996 .................................................. 24

3.11.1 Execution of program P99996 ....................................................................... 25

3.11.1.1 Tool inspection .............................................................................................. 26

3.11.1.2 Execution modes ............................................................................................ 27

3.11.1.3 CNC reset ....................................................................................................... 27

3.11.1.4 Displaying program blocks ............................................................................ 27

3.11.1.5 Display modes ................................................................................................ 28

3.11.2 Simulation of program P99996 ...................................................................... 30

3.11.2.1 Zoom function ................................................................................................ 31

3.12 Editing program P99996 ................................................................................ 32


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Chapter 4. MACHINE PARAMETERS

4.1 Introduction .................................................................................................... 1

4.2 Operation with parameter tables .................................................................... 2

4.3 General machine parameters........................................................................... 34.3.1 I/O parameters................................................................................................. 5

4.3.2 Handwheel parameters .................................................................................... 8

4.3.3 Operating-mode parameters ............................................................................ 11

4.3.4 Tool parameters .............................................................................................. 14

4.3.5 RS232C serial line parameters ....................................................................... 16

Chapter 5. MACHINE PARAMETERS FOR THE AXES

5.1 Machine parameters for axis resolution ......................................................... 2

5.2 Machine parameters for axis analog outputs ................................................. 4

5.3 Machine parameters for the travel limits of the axes .................................... 55.4 Machine parameters for the leadscrews ......................................................... 6

5.5 Machine parameters for axis feedrates ........................................................... 7

5.6 Machine parameters for axis control .............................................................. 9

5.7 Machine parameters for machine reference zero ............................................ 11

5.8 Machine parameters for acceleration/deceleration of the axes...................... 13

5.8.1 Linear acceleration / deceleration.................................................................. 13

5.8.2 Bell-shaped acceleration /deceleration ramp ................................................. 14

5.8.3 Feed-forward gain ........................................................................................... 15

5.9 Parameters for the live tool ............................................................................ 16

5.10 Special machine parameters ........................................................................... 17

Chapter 6. SPINDLE MACHINE PARAMETERS

6.1 Machine parameters for spindle speed range change .................................... 2

6.2 Machine parameters for analog spindle speed output ................................... 4

6.3 Machine parameters for spindle speed output in BCD.................................. 5

6.4 Machine parameters for spindle control ........................................................ 7

6.4.1 Parameters related to spindle orientation....................................................... 9


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Chapter 7. CONCEPTS7.1 Feedback systems ........................................................................................... 1

7.1.1 Counting frequency limits ............................................................................. 2

7.1.2 Resolution of X and Z axes ........................................................................... 3

7.2 Adjustment of X and Z axes........................................................................... 8

7.2.1 Offset and maximum feedrate adjustment ...................................................... 9

7.2.2 Gain adjustment for X and Z axes ................................................................. 11

7.2.2.1 Proportional gain adjustment ......................................................................... 12

7.2.2.2 Calculation of K1, K2 and gain break-point ................................................. 14

7.3 Reference points for X and Z axes................................................................. 16

7.3.1 Machine reference search (home) ................................................................... 17

7.3.2 Considerations ................................................................................................ 18

7.3.3 Adjustment of the value corresponding to the Machine Reference Point .... 19

7.3.4 Axis software travel limits .............................................................................. 20

7.4 Acceleration/deceleration ............................................................................... 21

7.4.1 Calculation of feed-forward gain ................................................................... 21

7.4.2 Acceleration/deceleration on linear interpolations ........................................ 227.4.3 Acceleration/deceleration on all types of movements .................................. 22

7.5 Handwheel movements................................................................................... 23

7.5.1 The machine has mechanical handwheels ..................................................... 23

7.5.2 The machine has a single electronic handwheel ........................................... 23

7.5.3 The machine has two electronic handwheels ................................................. 25

7.6 Spindle ............................................................................................................ 27

7.6.1 Spindle speed range change ........................................................................... 30

7.6.1.1 Manual spindle range change ........................................................................ 30

7.6.1.2 Automatic spindle range change .................................................................... 31

7.6.2 Spindle control ............................................................................................... 33

7.7 Tools and tool magazine ................................................................................ 34

7.7.1 Machine with an automatic tool changer ...................................................... 347.7.2 Machine without an automatic tool changer ................................................. 34

7.7.3 Tool change position ..................................................................................... 35

7.8 Feed-hold and M-done signal processing ...................................................... 36

7.9 M, S, T function transfer ................................................................................ 37

7.9.1 M, S, T function transfer using the M-done signal ....................................... 38

7.9.2 "M" function transfer without M-done signal................................................ 40

APPENDICES

A Technical characteristics of the 800T CNC ................................................... 2

B Enclosures....................................................................................................... 6

C Logic inputs and outputs ............................................................................... 8

D 2-digit BCD coded "S" output conversion table ........................................... 9

E Machine parameter summary chart ................................................................. 10

F Sequential machine parameter list ................................................................. 14

G Machine parameter setting charts .................................................................. 19

H Maintenance ................................................................................................... 21

ERROR CODES


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COMPARISON TABLEFOR FAGOR 800T

CNC MODELS


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800-T 800-TI 800-TG 800-TGI

X, Z axes controll l l l

Spindle control l l l l

Spindle in RPM l l l l

Constant Surface Speed (CSS) l l l l

Spindle Orientation l l l l

Tools 32 32 32 32

Tool Compensation l l l l

Live Tool l l l l

Electronic Handwheels 2 2 2 2

RS 232C Communications l l l l

Integrated PLC (PLCI) l l

ISO-coded program editing

(P99996)l l l l

Execution of ISO-coded

program (P99996)l l l l

Graphics l l

AVAILABLE 800T CNC MODELS

Compact model with 8" amber CRT.

Modular model with 9" amber Monitor.

Consisting of Central Unit, Monitor and Keyboard.

Modular model with 14" Color Monitor

Consisting of Central Unit, Monitor and Keyboard.

TECHNICAL DESCRIPTION


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NEW FEATURESAND

MODIFICATIONS

Date: April 1993 Software Version: 2.1 and newer

FEATURE AFFECTED MANUAL AND SECTION

Rapid jog depending on position of Feedrate Override Switch Operating Manual Section 2.3.1

Tool for the finishing pass Installation Manual Section 3.5Operating Manual Section 3.5

Handwheel movement limited to maximum Operating Manual Section 2.3.3allowed F

Control of software travel limits when using ahandwheel

Display format for S Installation Manual Section 6

Possibility to activate/deactivate outputs O1,O2, O3 after interrupting the program

Automatic operation "Profile Rounding" Operating Manual Section 5.5.3

Profiles Operating Manual Chapter 6

Date: October 1993 Software Version: 3.1 and newer


Spindle acc./dec. Operating Manual Chapter 6

RPM Limitation when operating in CSS Operating Manual Section 4.3.1

Spindle orientation Installation Manual Section 6.4.1Operating Manual Section 4.8

Live tool Installation Manual Section 5.9Operating Manual Section 2.3

Automatic operation "Simple Drilling" Operating Manual Section 5.8

Automatic operation "Multiple Drilling" Operating Manual Section 5.9


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Date: December 1993 Software Version: 3.2 and newer

FEATURES AFFECTED MANUAL AND SECTION

Assign a 5-digit number to the part program Operating Manual Chapter 7

Save part programs out to a peripheral Operating Manual Section 7.7

Automatic operation "Slot milling" Operating Manual Section 5.10

Delay before opening the positioning loop Installation Manual Section 4.3.2

"Special modes" accessing password Installation Manual Section 3.7

Handwheel inactive when Feedrate Override Installation Manual Section 4.3.2Switch out of handwheel positions

Date: July 1994 Software Version: 4.1 and newer


Linear and Bell-shaped spindle acc./dec. Installation Manual Section 5.8

Profile with/without corner rounding. Operating Manual Section 6.2

Threading operation also with thread exit. Operating Manual Section 5.6.2

Rapid jog at 200% or depending on the Installation Manual Section 4.3.3position of the Feedrate Override Switch. Operating Manual Section 2.3.1

Tool inspection Installation Manual Section 3.4.3Operating Manual Section 3.4.3Operating Manual Section 5.1.3

Execution of program 99996 Installation Manual Section 3.11Operating Manual Section 3.10


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Date: January 1995 Software version: 5.1 and newer


M3/M44 confirmation by detecting feedbackreversal Installation Manual Section 6.4

JOG movements also in mm/rev

Handwheel governed by the PLCI Installation Manual Section 4.3.2

Spindle inhibit from PLCI PLCI Manual

Clear all arithmetic parameter contents setting Installation Manual Section 3.10them to "0". Operating Manual Section 3.9 & 7.9

Automatic rounding operation (Cycle level)with angle other than 90. Operating Manual Section 5.5.2

Automatic grooving operation on the faceof the part and finishing pass. Operating Manual Section 5.7

Automatic profile rounding operation by patternrepeat of profile or roughing. Operating Manual Section 5.5.3

Approach point in profile rounding operation(modification). Operating Manual Section 5.5.3

Automatic Profile execution, Cycle Level, bypattern repeat or roughing. Operating Manual Section 6.2

Approach point in automatic Profile execution

(modification). Operating Manual Section 6.2

Automatic tapping operation. Operating Manual Section 5.8

M20 at the end of part-program execution. Installation Manual Section 3.8.3.1

Graphic simulation Operating Manual Section 5.1.3

Execution / Simulation of program P99996 Installation Manual Section 3.11(ISO-coded user program) Operating Manual Section 3.10

Automatic or Single-block execution of P99996 Operating Manual Section 3.10

Editing of program P99996 Installation Manual Section 3.12Operating Manual Section 3.11Programming Manual

ISO-coded user program P99994 to storesubroutines Programming Manual Chapter 9

Subroutine associated to the execution of a tool Installation Manual Section 4.3.4(only when executing program P99996) Programming Manual

ISO codes of the 800T CNC Programming Manual


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Date: March 1995 Software version: 5.2 and newer


Editing of program P99996 in all models.

When interrupting the execution, the following Installation Manual Section 3.11

keys are enabled: spindle, coolant, O1, O2, O3 Operating Manual Section 3.10and TOOL. Operating Manual Section 5.1.4Operating Manual Section 7.5

Incremental JOG movements taking current Installation Manual Section 4.3.3work units (radius or diameter) into account.

ISO programming. New functions: G47, G48 Programming Manual Section 6.7(single block treatment).

ISO programming. New function: G86 Programming Manual Section 8.17(Longitudinal threadcutting canned cycle).

Request from the PLCI for real spindle rpm. PLCI Manual

Date: November 1995 Software version: 5.5 and newer


Tool offset modification while in execution. Operating Manual Section 3.4.4

Operation with a single electronic handwheel. Installation Manual Section 4.3.2Installation Manual Section 7.5

Actual "S" speed reading from the PLCI. PLCI Manual


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INTRODUCTION

Atention: Before starting up the CNC, carefully read the instructions of Chapter2 in the Installation Manual.

The CNC must not be powered-on until verifying that the machinecomplies with the "89/392/CEE" Directive.


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DECLARATION OF CONFORMITY

Manufacturer: Fagor Automation, S. Coop.

Barrio de San Andrs s/n, C.P. 20500, Mondragn -Guipzcoa- (ESPAA)

We hereby declare, under our responsibility that the product:

Fagor 800T CNC

meets the following directives:

SAFETY:

EN 60204-1 Machine safety. Electrical equipment of the machines.

ELECTROMAGNETIC COMPATIBILITY:

EN 50081-2 Emission

EN 55011 Radiated. Class A, Group 1.EN 55011 Conducted. Class A, Group 1.

EN 50082-2 Immunity

EN 61000-4-2 Electrostatic Discharges.EN 61000-4-4 Bursts and fast transients.EN 61000-4-11Voltage fluctuations and Outages.ENV 50140 Radiofrequency Radiated Electromagnetic Fields.ENV 50141 Conducted disturbance induced by radio frequency fields.

As instructed by the European Community Directives on Low Voltage: 73/23/EEC,on Machine Safety 89/392/EEC and 89/336/EEC on Electromagnetic Compatibility.

In Mondragn, on January 2nd, 1997


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SAFETY CONDITIONS

Read the following safety measures in order to prevent damage to personnel, tothis product and to those products connected to it.

This unit must only be repaired by personnel authorized by Fagor Automation.

Fagor Automation shall not be held responsible for any physical or materialdamage derived from the violation of these basic safety regulations.

Precautions against personal damage

Use proper Mains AC power cablesTo avoid risks, use only the Mains AC cables recommended for this unit.

Avoid electrical overloadsIn order to avoid electrical discharges and fire hazards, do not apply electrical voltageoutside the range selected on the rear panel of the Central Unit.

Ground connectionIn order to avoid electrical discharges, connect the ground terminals of all the modulesto the main ground terminal. Before connecting the inputs and outputs of this unit,make sure that all the grounding connections are properly made.

Before powering the unit up, make sure that it is connected to groundIn order to avoid electrical discharges, make sure that all the grounding connections

are properly made.

Do not work in humid environmentsIn order to avoid electrical discharges, always work under 90% of relative humidity(non-condensing) and 45 C (113 F).

Do not work in explosive environmentsIn order to avoid risks, damage, do not work in explosive environments.

Precautions against product damage

Working environmentThis unit is ready to be used in Industrial Environments complying with the directivesand regulations effective in the European Community

Fagor Automation shall not be held responsible for any damage suffered or causedwhen installed in other environments (residential or homes).

Install the unit in the right placeIt is recommended, whenever possible, to instal the CNC away from coolants,chemical product, blows, etc. that could damage it.

This unit complies with the European directives on electromagnetic compatibility.Nevertheless, it is recommended to keep it away from sources of electromagneticdisturbance such as.


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- Powerful loads connected to the same AC power line as this equipment.- Nearby portable transmitters (Radio-telephones, Ham radio transmitters).- Nearby radio / TC transmitters.- Nearby arc welding machines- Nearby High Voltage power lines- Etc.

EnclosuresThe manufacturer is responsible of assuring that the enclosure involving the equipmentmeets all the currently effective directives of the European Community.

Avoid disturbances coming from the machine toolThe machine-tool must have all the interference generating elements (relay coils,contactors, motors, etc.) uncoupled.

Use the proper power supplyUse an external regulated 24 Vdc power supply for the inputs and outputs.

Grounding of the power supplyThe zero volt point of the external power supply must be connected to the main groundpoint of the machine.

Analog inputs and outputs connectionIt is recommended to connect them using shielded cables and connecting their shields(mesh) to the corresponding pin (See chapter 2).

Ambient conditionsThe working temperature must be between +5 C and +45 C (41F and 113 F)The storage temperature must be between -25 C and 70 C. (-13 F and 158 F)

Monitor enclosureAssure that the Monitor is installed at the distances indicated in chapter 1 from the

walls of the enclosure.

Use a DC fan to improve enclosure ventilation.

Main AC Power SwitchThis switch must be easy to access and at a distance between 0.7 m (27.5 inches) and1.7 m (5.6 ft) off the floor.

Protections of the unit itself

It carries two fast fuses of 3.15 Amp./ 250V. to protect the mains AC input.

All the digital inputs and outputs have galvanic isolation via optocouplers betweenthe CNC circuitry and the outside.

They are protected by an external fast fuse (F) of 3.15 Amp./ 250V. against overvoltage and reverse connection of the power supply.

The type of fuse depends on the type of monitor. See the identification label of the unit.


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Precautions during repair

Do not manipulate the inside of the unitOnly personnel authorized by Fagor Automation may manipulate theinside of this unit.

Do not manipulate the connectors with the unit connected to AC

power.Before manipulating the connectors (inputs/outputs, feedback, etc.)make sure that the unit is not connected to AC power.

Safety symbols

Symbols which may appear on the manual

WARNING. symbolIt has an associated text indicating those actions or operations may hurtpeople or damage products.

Symbols that may be carried on the product

WARNING. symbolIt has an associated text indicating those actions or operations may hurtpeople or damage products.

"Electrical Shock" symbolIt indicates that point may be under electrical voltage

"Ground Protection" symbolIt indicates that point must be connected to the main ground point of themachine as protection for people and units.


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WARRANTY TERMS

WARRANTY

All products manufactured or marketed by Fagor Automation has a warranty periodof 12 months from the day they are shipped out of our warehouses.

The mentioned warranty covers repair material and labor costs, at FAGOR facilities,incurred in the repair of the products.

Within the warranty period, Fagor will repair or replace the products verified as beingdefective.

FAGOR is committed to repairing or replacing its products from the time when thefirst such product was launched up to 8 years after such product has disappeared from

the product catalog.

It is entirely up to FAGOR to determine whether a repair is to be considered underwarranty.

EXCLUDING CLAUSES

The repair will take place at our facilities. Therefore, all shipping expenses as well astravelling expenses incurred by technical personnel are NOT under warranty evenwhen the unit is under warranty.

This warranty will be applied so long as the equipment has been installed accordingto the instructions, it has not been mistreated or damaged by accident or negligenceand has been manipulated by personnel authorized by FAGOR.

If once the service call or repair has been completed, the cause of the failure is not tobe blamed the FAGOR product, the customer must cover all generated expensesaccording to current fees.

No other implicit or explicit warranty is covered and FAGOR AUTOMATION shallnot be held responsible, under any circumstances, of the damage which could beoriginated.

SERVICE CONTRACTS

Service and Maintenance Contracts are available for the customer within the warrantyperiod as well as outside of it.


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MATERIAL RETURNING TERMS

When returning the CNC, pack it in its original package and with its original packagingmaterial. If not available, pack it as follows:

1.- Get a cardboard box whose three inside dimensions are at least 15 cm (6 inches) largerthan those of the unit. The cardboard being used to make the box must have aresistance of 170 Kg (375 lb.).

2.- When sending it to a Fagor Automation office for repair, attach a label indicating theowner of the unit, person to contact, type of unit, serial number, symptom and a briefdescription of the problem.

3.- Wrap the unit in a polyethylene roll or similar material to protect it.

When sending the monitor, especially protect the CRT glass.

4.- Pad the unit inside the cardboard box with poly-utherane foam on all sides.

5.- Seal the cardboard box with packing tape or industrial staples.


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ADDITIONAL REMARKS

* Mount the CNC away from coolants, chemical products, blows, etc. which coulddamage it.

* Before turning the unit on, verify that the ground connections have been properly made.See Section 2.2 of this manual.

* To prevent electrical shock at the Central Unit, use the proper mains AC connector atthe Power Supply Module. Use 3-wire power cables (one for ground connection)

* To prevent electrical shock at the Monitor, use the proper mains AC connector at thePower Supply Module. Use 3-wire power cables (one for ground connection)

* Before turning the unit on, verify that the external AC line fuse, of each unit, is the rightone.

Central UnitMust be 2 fast fuses (F) of 3.15 Amp./ 250V.


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MonitorDepends on the type of monitor. See identification label of the unit itself.

* In case of a malfunction or failure, disconnect it and call the technical service. Do notmanipulate inside the unit.


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FAGOR DOCUMENTATIONFOR THE 800T CNC

800T CNC OEM Manual Is directed to the machine builder or person in charge of installing and startingup the CNC.

It has the Installation manual inside. Sometimes, it may contain an additionalmanual describing New Software Features recently implemented.

800T CNC USER Manual Is directed to the end user or CNC operator.

It contains 2 manuals:Operating Manual describing how to operate the CNC.Programming Manual describing how to program the CNC.

Sometimes, it may contain an additional manual describing New SoftwareFeatures recently implemented.

DNC 25/30 Software Manual Is directed to people using the optional DNC communications software.

DNC 25/30 Protocol Manual Is directed to people wishing to design their own DNC communications softwareto communicate with the 800 without using the DNC25/30 software..

PLCI Manual To be used when the CNC has an integrated PLC.

Is directed to the machine builder or person in charge of installing and startingup the PLCI.

DNC-PLC Manual Is directed to people using the optional communications software: DNC-PLC.

FLOPPY DISK Manual Is directed to people using the Fagor Floppy Disk Unit and it shows how to useit.


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MANUAL CONTENTS

The installation manual consists of the following sections:

Index

Comparative Table for Fagor 800T CNC models

New Features and modifications

Introduction Warning sheet prior to start-upDeclaration of ConformitySafety ConditionsWarranty termsShipping conditionsAdditional remarksFagor documents for the 800T CNCManual Contents

Chapter 1 CNC configurationIndicates the possible compositions: modular and compact

Indicates the Central Unit dimensionsIndicates the Monitor dimensionsIndicates the Operator panel dimensionsDetailed description of all the connectors.

Chapter 2 Power and machine connection.Indicates how to connect it to Main AC power.Ground connection.Characteristics of the digital inputs and outputs.Characteristics of the analog output.Characteristics of the feedback inputsCNC setup and start-upSystem I/O testingConnection of the Emergency input and output.

Chapter 3 Auxiliary functions.Indicates how to select the work units (mm/inches).How to select radius or diameter working modesHow to select feedrate units (mm/min or mm/rev).How to define the tool table.How to calibrate and inspect a tool.How to define the finishing pass for the automatic operationsHow to define the safety distance for automatic operationsHow to select and define the automatic operations:

Simple drilling, multiple drilling and slot milling.How to run a system test.How to access the machine parameters.How to access and operate with the decoded "M" functions.How to apply leadscrew error compensation.How to operate with peripherals.

How to lock and unlock the machine parameters and the program memory.How to edit, execute and simulate program 99996.

Chapter 4 Machine parameters.How to operate with machine parameters.How to set the machine parameters.Detailed description of the general machine parameters.

Chapter 5 Machine parameters for the axes.Detailed description of the machine parameters for the axes.

Chapter 6 Machine parameters for the spindle.Detailed description of the machine parameters for the spindle.


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Chapter 7 Concepts.Feedback systems, resolutionAdjustment of the axes and their gains.Reference Systems: Reference systems, search and settingSoftware travel limits for the axes.Acceleration / deceleration.Spindle: speed control and range change.Tools and tool magazine"Feed Hold" and "M-done" signal processing (treatment)

Auxiliary M, S, T function transfer

Appendix A CNC technical characteristics.B Enclosures.C CNC inputs and outputs.D 2-digit BCD coded spindle "S" outputE Machine parameter summary chartF Sequential machine parameter listingG Machine parameter setting chartH Maintenance

Error Codes


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PageChapter: 1 Section:

1800T CNC CONFIGURATION

1. 800T CNC CONFIGURATION

Atention:

The CNC is prepared to be used in Industrial Environments, especially onmilling machines, lathes, etc. It can control machine movements and devices.

It can control machine movements and devices.

1.1 INTRODUCTION

You have just received one of the models listed below:

Compact 800T CNC with 8" amber monitorModular 800T CNC with 9" amber monitorModular 800T CNC with 14" color monitor

This chapter describes the configuration of both compact and modular models as wellas the dimensions of the 9" amber and 14" color monitors.

1.2 COMPACT 800T CNC

The compact 800T CNC is an enclosed module having the following elements on itsfront panel:

1. One 8" monochrome amber monitor or CRT to display the system data.

2. A keyboard to communicate with the CNC and be able to request or alter thestatus of the CNC by generating new instructions.

3. An operator panel with the necessary keys to operate in JOG mode and the Cycle

Start and Cycle Stop keys.

COMPACT 800T CNC


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Section:Chapter: 1Page

2 800T CNC CONFIGURATION

1.2.1 DIMENSIONS & INSTALLATION OF THE COMPACT 800T CNC

This CNC, usually located on the machine's operator panel, has 4 mounting holes.

When installing it, leave enough room to swing the cover open in order to be able to

get to its interior in the future if necessary.

To open it, undo the 4 allen screws next to the CNC mounting holes.

COMPACT 800T CNC


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1.3 MODULAR 800T CNC

The 800T CNC consists of 3 independent interconnected modules. These modulesmay be mounted on different locations of the machine and they are:

- CENTRAL UNIT- MONITOR- KEYBOARD

The CENTRAL UNIT communicates with the MONITOR via the provided videosignal cable which may be up to 25m long (82ft).

The CENTRAL UNIT communicates with the KEYBOARD via the provided keyboardsignal cable which may be up to 25m long (82ft).

MODULAR 800T CNC


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1.3.1 CENTRAL UNIT OF THE MODULAR 800T CNC

The CENTRAL UNIT is usually mounted in the electrical cabinet by means of themounting holes located at the SUPPORT lid (cover).

All dimensions are in mm.

When installing it, it must be assigned enough room to swing it open in order to gainaccess to its interior.

To swing the central unit open, undo the two knurled nuts located on the back andswing it while supporting its body.

MODULAR 800T CNC(central unit)


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1.3.2 MONITOR OF THE MODULAR 800T CNC

It may be mounted anywhere on the machine, but it is recommended to be at operator'seye level. All dimensions are in mm.

Atention:

Do not manipulate inside this unitOnly personnel authorized by Fagor Automatin may manipulate insidethis module.

Do not manipulate the connectors with the unit connected to main ACpower

Before manipulating these connectors, make sure that the unit is notconnected to main AC power.

9" Amber Monitor.

MODULAR 800T CNC(monitor)


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It has:

1.- Brightness adjustment knob for the MONITOR screen.

2.- Contrast adjustment knob for the MONITOR screen.

3.- Two AC power fuses. One per line for power input protection (3A. 250V.)

4.- Power ON/OFF switch.

5.- AC power plug. Use the supplied plug to connect it to 220V AC and ground.

6.- Ground terminal. Used to connect the general machine ground. It is Metric6mm.

7.- 15-pin SUB-D type male connector to connect the MONITOR with theCENTRAL UNIT.

This connector is described in the section corresponding to the CENTRALUNIT.


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14" Color Monitor. (Dimensions in mm)

It has a back-pack with the following elements:

X2. 15-pin SUB-D type male connector to connect the MONITOR with theCENTRAL UNIT.


1.- Ground terminal. Used to connect the general machine ground. It is Metric6mm.

2.- AC power plug. Use the supplied plug to connect it to 220V AC and ground.

1.3.2.1 MONITOR ENCLOSURE

Consult the appendix on "ENCLOSURES" at the end of this manual for proper

dimensioning and ventilation.



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Outside shield soldered

to metal hood

Heat-shrink

Shield

Metal hood


1.3.2.2 MONITOR-CENTRAL UNIT CONNECTION CONNECTOR

It is a 15-pin SUB-D type female connector used to connect the MONITOR with theCENTRAL UNIT.

FAGOR AUTOMATION supplies the cable required for this connection and it consistsof a cable with a 15-pin SUB-D type connectors at each end, one male and the otherone female.

Both connectors have a latching system by means of two UNC4.40-type screws.

PIN SIGNAL

1 GND

2 H3 V4 I5 R

6 G7 B8 Not connected9 Not connected

10 H

11 V

12 I13 R14 G15 B

Metal housing shield

The cable being used has 6 twisted pairs with a section of 0.34 mm each (6 x 2 x0.34mm) with overall shielding and acrylic rubber covering. Its specific impedanceis 120 Ohm and the maximum length permitted is 25m (82ft.).

The cable shield is soldered to the metal housing of both cable connectors and it isconnected to pin 1 of the female connector at the Central Unit as well as at the Monitor.


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1.3.3 KEYBOARD OF THE MODULAR 800T CNC

The keyboard may be mounted anywhere on the machine.

All dimensions are in mm.

On its back it has:

1.- 25-pin SUB-D type female connector to connect the KEYBOARD to theCENTRAL UNIT.


2.- Potentiometer to adjust the volume of the buzzer.

3.- Buzzer.

MODULAR 800T CNC(keyboard)


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10 800T CNC CONFIGURATION MODULAR 800T CNC(keyboard)

1.3.3.1 KEYBOARD-CENTRAL UNIT CONNECTION CONNECTOR

It is a 25-pin SUB-D type female connector used to connect the KEYBOARD withthe CENTRAL UNIT.

FAGOR AUTOMATION supplies the cable required for this connection which consistsof a cable with a 25-pin SUB-D type male connector at each end.

Both connectors have a latching system by means of two UNC4.40-type screws.

PIN SIGNAL

1 GND

2 C93 C114 C135 C15

6 C17 C38 C59 C7

10 D1

11 D3

12 D513 D714 C815 C10

16 C1217 C1418 C019 C220 C4

21 C622 D0

23 D224 D425 D6

Metal housing shield

The cable has 25 wires with a section of 0.14 mm each (25 x 0.14mm) with overallshielding and acrylic rubber covering. The maximum permissible length is 25m (82ft.).


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The cable shield is soldered to the metal housing of both cable connectors and it isconnected to pin 1 of the female connector at the Central Unit as well as at the Keyboard.

Outside shield solderedto metall ic housing

Metallic housing

ShieldHeat shrink

MODULAR 800T CNC(keyboard)


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1.4 CONNECTORS AND CONNECTIONS OF THE 800T CNC SYSTEM

A1 15-pin SUB-D type female connector for X axis feedback connection. It acceptssinusoidal signal.

A2 15-pin SUB-D type female connector. Not being used at this time.

A3 15-pin SUB-D type female connector for Z axis feedback connection. It acceptssinusoidal signal.

A4 15-pin SUB-D type female connector for 2nd electronic handwheel connection(for the Z axis). It accepts sinusoidal signal.

A5 15-pin SUB-D type female connector for spindle feedback connection.It doesnot accept sinusoidal signal.

A6 9-pin SUB-D type female connector for 1st electronic handwheel connection(for X axis only when having two handwheels). It does not accept sinusoidalsignal.

RS485 9-pin SUB-D type female connector. Not being used at this time.

RS232C 9-pin SUB-D type female connector for serial port RS 232C connection.

I/O1 37-pin SUB-D type female connector for interface connection with the electricalcabinet.

I/O2 25-pin SUB-D type female connector for interface connection with the electricalcabinet.

CONNECTORS ANDCONNECTIONS


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1.- Main AC fuse. It has two 3.15Amp./250V. fast fuses (F), one per AC line, toprotect the main AC input.

2.- AC power plug. To supply AC voltage to the CNC by connecting it to thetransformer and to ground.

3.- Ground terminal. Metric 6mm. Where the general machine ground must beconnected.

4.- Fuse. 3.15Amp./250V fast fuse (F) to protect the internal I/O circuitry of theCNC.

5.- Lithium battery. It provides power back-up for data contained in RAM memory.

6.- Potentiometers for analog output adjustment. To be used only by the TechnicalService Department at FAGOR AUTOMATION.

7.- 10 dip-switches. There are 2 dip-switches under each feedback input (A1 thruA5) to set the CNC according to the type of feedback signals being used in eachcase.

8.- 25-pin SUB-D type female connector to connect the KEYBOARD to theCENTRAL unit.

9.- 15-pin SUB-D type female connector to connect the MONITOR to the CENTRALunit.

10.-Heat-sink.

Atention:



CONNECTORS ANDCONNECTIONS


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1.4.1 CONNECTORS A1, A3, A4

They are 15-pin SUB-D type connectors used to connect feedback devices.

* Connector A1 is used for the X axis feedback signals.* Connector A3 is used for the Z axis feedback signals.* Connector A4 is used for the 2nd handwheel (for the Z axis) feedback signals.

The type of cable used must have overall shield. The rest of its characteristics suchas length will depend on the type and model of the feedback device being used.

It is highly recommended to run these cables as far away as possible from the powercables of the machine.

PIN MEANING AND FUNCTION

1 A2 A Differential square-wave feedback signals.3 B4 B

5 Io Machine reference pulse signals (Marker).6 Io

7 Ac Sine-wave feedback signals.8 Bc

9 +5V. Power to feedback device.10 Not connected.11 0V. Power to feedback device.12 Not connected.13 -5V. Power to feedback device.14 Not connected.

15 FRAME Shield.

Atention:

When using square-wave rotary encoders, their output signals must be TTLcompatible and their outputs must not be Open Collector.



CONNECTORS A1, A3, A4


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1.4.1.1 DIP-SWITCHES FOR CONNECTORS A1, A3, A4

There are 2 dip-switches under each feedback input connector (A1, A3 and A4) to setthe CNC according to the type of feedback signal being used in each case.

Dip-switch 1 indicates whether the feedback signal is sine-wave or square-wave anddip-switch 2 indicates whether the feedback signal is differential (double-ended) ornot (single-ended).

The feedback signals that can be used at connectors A1, A3 and A4 are:

* Sine-wave feedback signals: Ac, Bc, Io* Square-wave feedback signals: A, B, Io* Differential (double-ended) square-wave feedback signals:

The chart below shows the dip-switch combinations for the particular type of feedback

signal used at each feedback input.

Dip-switch FUNCTION1 2

ON ON Sine-wave signal (Ac, Bc, Io)ON OFF Differential sine-wave signal "not allowed"OFF ON Square-wave signal (A,B,Io)OFF OFF Differential square-wave signal (A,A,B,B,Io,Io)

There is a label next to each pair of switches indicating their meaning.

A, A, B, B, Io, Io

CONNECTORS A1, A3, A4


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1.4.2 CONNECTOR A5

It is a 15-pin SUB-D type female connector used to connect the spindle feedbackdevice. It does not take sine-wave signals.




1 A2 A Differential square-wave feedback signals.

3 B4 B

5 Io Machine Reference pulses (Marker).6 Io

7 Not being used at this time.8 Not being used at this time.

9 +5V. Power to feedback device.10 Not connected.11 0V. Power to feedback device.

12 Not connected.13 -5V. Power to feedback device.14 Not connected.

15 FRAME Shield.

Atention:

When using square-wave rotary encoders, their output signals must be TTLcompatible and their outputs must not be Open Collector.



CONNECTOR A5


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1.4.2.1 DIP-SWITCHES FOR CONNECTOR A5

There are 2 dip-switches under connector A5 to set the CNC according to the type offeedback signal being used in each case.

Dip-switch 1 indicates whether the feedback signal is sine-wave or square-wave anddip-switch 2 indicates whether the feedback signal is differential (double-ended) ornot (single-ended).

The feedback signals that can be used at connector A5 are:

* Square-wave feedback signals: A, B, Io* Differential (double-ended) square-wave feedback signals:

The chart below shows the dip-switch combinations for the particular type of feedbacksignal used at this connector.

Dip-switch FUNCTION1 2

ON ON Sine-wave signal "not allowed"ON OFF Differential sine-wave signal "not allowed"OFF ON Square-wave signal (A,B,Io)OFF OFF Differential square-wave signal (A,A,B,B,Io,Io)

There is a label next to these switches indicating their meaning.

A, A, B, B, Io, Io

CONNECTOR A5


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1.4.3 CONNECTOR A6

It is a 9-pin SUB-D type female connector used to connect the feedback device forthe first electronic handwheel. It does not take sine-wave signals.




1 A Square-wave feedback signals

2 B from the electronic handwheel.

3 Io Machine Reference pulse signal

4 +5V. Power for the electronic handwheel.5 0V. Power for the electronic handwheel.

6 Not being used at this time.7 Not being used at this time.8 Not being used at this time.

9 FRAME Shield.

Atention:

When the handwheel supplies square-wave pulses they must be TTLcompatible and the outputs must not be Open Collector.

When using a FAGOR 100P model handwheel, the axis selector signalmust be connected to pin 3.

Do not manipulate the connectors with the unit connected to main ACpowerBefore manipulating these connectors, make sure that the unit is notconnected to main AC power.

CONNECTOR A6


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1.4.4 RS232C CONNECTOR

It is a 9-pin SUB-D type female connector used to connect the RS-232C serial line.

The shield of the cable being used must be connected to pin 1 of the connector at theCNC end and to the metal housing of the connector at the PERIPHERAL end.

PIN SIGNAL FUNCTION

1 FG Shield.2 TxD Transmit Data3 RxD Receive Data4 RTS Request To Send5 CTS Clear To Send

6 DSR Data Send Ready7 GND Ground8 - Not connected9 DTR Data Terminal Ready

SUGGESTIONS FOR RS232C INTERFACE

* Connecting and disconnecting the peripheral device

The CNC must be powered off when connecting or disconnecting

any peripheral device via this connector.

* Cable length

The EIA RS232C standards specify that the capacity of the cable must not exceed2500pF, thus, since the cables usually have a capacity between 130 and 170 pF/m, their maximum length will be limited to 15 meters (50 feet).

It is suggested to use shielded cables and/or twisted-pair wires in order to minimizeinterference between cables thus avoiding faulty communications over lengthycables.

It is recommended to use 7-conductor cables with a minimum section of 0.14 mmand overall shielding.

* Transmission speed (baudrate)

The most common baudrate used with peripherals is 9600 baud; but the CNC canoperate at up to 19200 baud.

All unused wires should be grounded to avoid erroneous control and data signals.

* Ground connection

It is suggested to reference all control and data signals to the same ground wire(pin 7 -GND-) thus avoiding reference points at different voltage levels since therecould be different voltages between both ends of long cables.

RS232C CONNECTOR


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RECOMMENDED RS232C INTERFACE CONNECTIONS

* Complete connection

* Simplified connection

To be used when the computer or peripheral device meets one of the followingrequirements:

It does not have the RTS signal orThe receiving unit can receive data at the selected baudrate.

However, it is recommended to consult the technical manuals of the computer orperipheral device in case there are any discrepancies.

CNC PERIPHERAL(9 pin connector) (25 pin connector)

FG 1

TxD 2

RxD 3

RTS 4

CTS 5

DSR 6

DTR 9

GND 7

1 FG

2 TxD

3 RxD

4 RTS

5 CTS

6 DSR

20 DTR

7 GND

HOUSING

CNC PC/AT COMPUTER(9 pin connector)

HOUSING

FG 1

TxD 2

RxD 3

CTS 5

DSR 6

DTR 9

GND 7

1 FG

2 RxD

3 TxD

8 CTS

6 DSR

4 DTR

5 GND

(9 pin connector)

1 FG

2 TxD

3 RxD

5 CTS

6 DSR

20 DTR

7 GND

FG 1

TxD 2

RxD 3

CTS 5

DSR 6

DTR 9

GND 7

HOUSING

COMPUTER PC/XT/PS2CNC

(25 pin connector)(9 pin connector)

RS232C CONNECTOR


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21800T CNC CONFIGURATION RS232C CONNECTOR


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1.4.5 CONNECTOR I/O 1

It is a 37-pin SUB-D type female connector to connect the CENTRAL UNIT to theelectrical cabinet.

Pin SIGNAL AND FUNCTION

1 0V. External power supply input.

2 T Strobe Output. The BCD code indicates tool number.

3 S Strobe Output. The BCD code indicates S spindle speed.

4 M Strobe Output. The BCD code indicates the M function number.

5 Emergency Output.

6 Threading ON Output.

7 Z Enable Output.

8 Reset Output.

9 X Enable Output.

10 X home switch Home switch input for the X axis.11 Not being used at this time.

12 Z home switch Home switch input for the Z axis.

13 Not being used at this time.

14 Emergency stop Input.

15 Feed Hold Input.

16 Stop Input.

17 Start Input.

18 Not being used at this time.

19 Manual Input. The CNC works as a DRO.

20 MST80 Output. BCD code, significance: 80








28 FRAME Connect all the shields used to this pin

29 24V. External power supply.

30 10V Analog output for the X axis drive.

31 0V. Analog output for the X axis drive.

32 10V Analog output for the live tool.

33 0V. Analog output for the live tool.

34 10V Analog output for the Z axis drive.

35 0V. Analog output for the Z axis drive.36 10V Analog output for the spindle drive.

37 0V. Analog output for the spindle drive.

Atention:The machine manufacturer must comply with the EN 60204-1 (IEC-204-1) regulation regarding the protection against electrical shock derived fromdefective input/output connection with the external power supply when thisconnector is not connected before turning the power supply on.



CONNECTOR I/O 1


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1.4.5.1 LOGIC INPUTS OF CONNECTOR I/O1

X AXIS HOME SWITCH. Pin 10

This INPUT must be high when the home switch for the X axis is pressed.

Z AXIS HOME SWITCH. Pin 12

This INPUT must be high when the home switch for the Z axis is pressed.

EMERGENCY STOP Pin 14

This INPUT must be normally high (24V).

When set low (0V), the CNC deactivates the enables and cancels the analog outputsof all the axes; it interrupts the execution of the part program and it displays ERROR

64.

It does not activate the emergency output at pin 5 of this connector.

FEED HOLD / TRANSFER INHIBIT / M DONE Pin 15

This input must be normally high (24V) and its meaning depends on the type ofblock or function being executed.

* Work as FEED-HOLD. If this input is set low (0V) while moving the axes, theCNC keeps the spindle on and stops the movement of the axes by cancellingtheir analog outputs (0V) but keeping their enables activated.

When returning this signal high, the CNC will resume the axes movement.

* Work as TRANSFER INHIBIT. If this input is set low while executing amotionless block, The CNC interrupts the execution of the program at the endof the current block.

When returning this signal high, the CNC will resume the execution of theprogram.

* The "M-DONE" signal will be used when machine parameter "P602" bit 7 hasbeen set to "1".

The CNC waits for the electrical cabinet to execute the requested M functionand return the "M-DONE" signal by setting this input high (24V).

CONNECTOR I/O 1(Inputs)


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STOP Pin 16

This INPUT must be normally high (24V).

When set low (0V), the CNC interrupts the program execution. It works just asthe key on the operator panel.

To resume program execution it is necessary to bring this signal up (24V) and

either press at the OPERATOR PANEL or activate the "START" input

described below.

START Pin 17

This INPUT must be normally low (0V) and connected to 0V through a 10KOhmresistor.

When an up flank (leading edge) is detected (level change from 0V to 24V), theCNC acts as if the key of the OPERATOR PANEL were pressed.

To use only this input instead ofthe key of the OPERATOR PANEL,machine parameter P601 bit 5 must be set to "1".

MANUAL (DRO mode) Pin 19

By setting this INPUT high (24V), the CNC behaves as a DRO.

CONNECTOR I/O 1(Inputs)


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1.4.5.2 LOGIC OUTPUTS OF CONNECTOR I/O 1

T Strobe Pin 2

The CNC activates this output (by setting it high-24V) whenever the BCD codesent out via pins 20 thru 27 corresponds to a tool number (T function).

S Strobe Pin 3

The CNC activates this output (by setting it high-24V) whenever the BCD codesent out via pins 20 thru 27 corresponds to a spindle speed value (S function).

M Strobe Pin 4

The CNC activates this output (by setting it high-24V) whenever the BCD codesent out via pins 20 thru 27 corresponds to a miscellaneous M function.

EMERGENCY Pin 5

The CNC activates this output whenever an internal emergency condition is detected.

This output is normally high (24V) or low (0V) depending on the setting ofmachine parameter P604 bit 4.

THREADING ON / CYCLE ON Pin 6

This output is normally low (0V) and its meaning depends on the setting of machineparameter P605 bit 4.

P605 bit 4 = 0 THREADING ON.

The CNC activates this output (24V) during a threading operation.

P605 bit 4 = 1 CYCLE ON.

The CNC activates this output (24V) whenever it is executing an automaticoperation or a "BEGIN-START" , "END-START" type command.

Z ENABLE Pin 7

The CNC activates this output (24V) whenever the Z axis drive is to be enabled.

RESET Pin 8

This output is activated (24V), when the CNC is reset by pressing the [RESET]key.

The CNC maintains this signal active for 80 milliseconds.

CONNECTOR I/O 1(Outputs)


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X ENABLE Pin 9

The CNC activates this output (24V) whenever the X axis drive is to be enabled.

MST80 Pin 20MST40 Pin 21MST20 Pin 22MST10 Pin 23MST08 Pin 24MST04 Pin 25MST02 Pin 26MST01 Pin 27

The CNC uses these outputs to indicate to the electrical cabinet which M, S or Tfunction has been selected.

This information is BCD coded and the significance or weight of each one ofthem is indicated by the corresponding mnemonic.

For example, to select the first spindle speed range, the CNC will send out to theelectrical cabinet the code: M41

MST80 MST40 MST20 MST10 MST08 MST04 MST02 MST010 1 0 0 0 0 0 1

Besides these outputs, the "M-STROBE", "T-STROBE" or "S-STROBE" signalwill also be activated depending on the type of function been selected.

X axis analog output 10V. Pin 30X axis analog output 0V. Pin 31

These outputs supply the analog voltage to move the X axis. They must be connectedto the drive via a shielded cable.

Live tool analog output 10V. Pin 32Live tool analog output 0V. Pin 33

These outputs supply the analog voltage to move the live tool. They must beconnected to the drive via a shielded cable.

Z axis analog output 10V. Pin 34

Z axis analog output 0V. Pin 35

These outputs supply the analog voltage to move the Z axis. They must be connectedto the drive via a shielded cable.

Spindle analog output 10V.Pin 36Spindle analog output 0V. Pin 37

These outputs supply the analog voltage to move the spindle (S). They must beconnected to the drive via a shielded cable.



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1.4.6 CONNECTOR I/O 2

It is a 25-pin SUB-D type female connector used to connect the CENTRAL UNITto the electrical cabinet.

PIN SIGNAL AND FUNCTION

1 0V. Input from external power supply.2 0V. Input from external power supply.3 Output M1 Bit 1 of M function table.4 Output M2 Bit 2 of M function table.5 Output M3 Bit 3 of M function table.6 Output M4 Bit 4 of M function table.7 Output M5 Bit 5 of M function table.8 Output M6 Bit 6 of M function table.9 Output M7 Bit 7 of M function table.

10 Output M8 Bit 8 of M function table.11 Output M9 Bit 9 of M function table.12 Output M10 Bit 10 of M function table.13 Output M11 Bit 11 of M function table.14 Not being used at this time15 Not being used at this time16 Not being used at this time17 Not being used at this time18 Not being used at this time19 24V. Input from external power supply.20 24V. Input from external power supply.21 Work Output. Selected work mode.22 Output M15 Bit 15 of M function table.23 Output M14 Bit 14 of M function table.24 Output M13 Bit 13 of M function table.25 Output M12 Bit 12 of M function table.

Atention:

The machine manufacturer must comply with the EN 60204-1 (IEC-204-

1) regulation regarding the protection against electrical shock derived fromdefective input/output connection with the external power supply whenthis connector is not connected before turning the power supply on.

Do not manipulate the connectors with the unit connected to mainAC power


CONNECTOR I/O 2


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1.4.6.1 LOGIC OUTPUTS OF CONNECTOR I/O 2

Decoded M outputs Pins 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 22, 23, 24 and 25

These outputs correspond to the bits selected at the decoded M function table.

For example: If the table corresponding to the M41 function has been set as follows:

M41 000100100100100 (outputs being activated)00100100100100100 (outputs being deactivated)

The CNC will behave as follows every time the M41 function is executed (selectionof the first spindle speed range):

Outputs M01 / Coolant Pin 3

This output besides providing the value of bit 1 of the selected decoded M functionof the table, acts as output for the COOLANT.

When using this option, be careful not to use this bit for both functions since the CNCwill activate it in both cases.

However, the CNC maintains this output active as long as the coolant is selected evenwhen executing an M function which would deactivate this output.

WORK Pin 21

The CNC activates this OUTPUT on CNC power-up and it deactivates only when

accessing the tool table (by the operator) or the auxiliary modes (with OEM password).

This output becomes active again when returning to the standard work mode.

M01 M02 M03 M04 M05 M06 M07 M08 M09 M10 M11 M12 M13 M14 M15

Pin I/ O2 3 4 5 6 7 8 9 10 11 12 13 25 24 23 22

at 24V x x x x

at 0V x x x x x

Does not

modifyx x x x x x



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M14 / G00 Output Pin 23

This OUTPUT, besides providing the status of bit 14 of the decoded M functiontable, it can also indicate that G00 has been selected.

To do this, set machine parameter P604 bit 3 to "1". This way, this output willbe set high (24V) whenever the CNC is executing a rapid axis positioning move(in G00).

Be careful not to use the bit corresponding to this output when setting thedecoded M function table since the CNC will activate it in both cases.



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1MACHINE AND POWER INTERFACE POWER INTERFACE

2. POWER AND MACHINE INTERFACE

Atention:Power switch

This power switch must be mounted in such a way that it is esaily accessedand at a distance between 0.7 meters (27.5 inches) and 1.7 meters (5.5ft) off the floor.

Intall this unit in the proper placeIt is recommended to install the CNC away from coolants, chemicalproducts, possible blows etc. which could damage it.

2.1 POWER INTERFACE

On the back of the CENTRAL UNIT of the 800T CNC there is a three-prong connectorto be connected to AC power and to ground..

The AC power must be supplied via an independent 110VA shielded transformer with anoutput voltage between 100V AC and 240V AC +10% and -15%.

The power outlet for the equipment must be near it and with easy access to it.

In the case of a power surge or voltage overload it is recommended to wait for about 3minutes before connecting it back in order to avoid any damage to the power supply.

The MONITOR of the 800T CNC must be connected to 220V AC.

2.1.1 INTERNAL POWER SUPPLY

Inside the CENTRAL UNIT there is a power supply that provides the different requiredvoltages.

Besides the two outside fuses for AC input protection (one per line), it has an inside 5A. fusefor protection against overvoltage.


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2 MACHINE AND POWER INTERFACE MACHINE INTERFACE

2.2 MACHINE INTERFACE

2.2.1 GENERAL CONSIDERATIONS

The machine tool must have all interference generating elements decoupled (relay coils,contactors, motors, etc.).

* DC relay coils.

1N4000 type diodes.

* AC relay coils.

RC connected as close to the coils as possible with approximate values such as:

R 220 Ohm/1WC 0,2 F/600V

* A.C Motors.

RC connected between phases with values:

R 300 Ohm/6WC 0,47F/600V

Ground connection.

A proper ground connection in an electrical installation is essential in order to achieve:

* The protection of people against electrical discharges caused by any malfunction.

* The protection of electronic equipment against interference generated at the machineitself or by other electronic equipment near by which could cause erratic malfunctioningof the equipment.

Thus, all metallic parts must be connected to the same point and this, in turn, to ground. Itis essential to establish one or two main points in the installation where the elementsmentioned above will be connected.

Cables with sufficient section must be used in order to obtain an impedance as low aspossible and an effective interference suppression maintaining all installation componentsat the same voltage level with respect to ground.


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3MACHINE AND POWER INTERFACE MACHINE INTERFACE

Besides the proper grounding of the installation, the signal cables must be shielded andtwisted-pairs for greater necessary protection. The shield must be connected to a specificpoint avoiding ground loops which could cause undesirable effects. This grounding of theshield is done at the CNCs ground terminal.

Each element of the machine-tool/CNC installation must be connected to ground throughthe established main ground points. They will be conveniently set at a point close to themachine-tool itself and properly connected to the Main Ground Point.

When a second ground point is required, it is recommended to join both points by a cablewith a section of 8 mm2 or greater (or two 4 mm2).

It must be verified that the resistance measured between each connector housing and groundis less than 1 Ohm.

Ground connection diagram:

Chassis

Ground

Ground (for safety)


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4 MACHINE AND POWER INTERFACE

2.2.2 DIGITAL OUTPUTS.

This CNC has a number of optocoupled digital outputs which can be used to activate relays,and so forth.

All the outputs are galvanically insulated by means of optocouplers from the outside worldand they permit to commute a DC voltage supplied from the electrical cabinet of themachine.

The electrical characteristics of these outputs are:

Nominal voltage +24 V DC.Maximum voltage +30 V DC.Minimum voltage +18 V DC.Output voltage 2V < V DC.Maximum output current 100 mA.

All the outputs are protected by:

Galvanic insulation by means of optocouplers.External 3A fuse against output overloads greater than 125mA, overvoltage of theexternal power supply greater than 33V DC and for protection against reversedconnection of the power supply.

2.2.3 DIGITAL INPUTS.

The digital inputs are used to read external devices and so forth.All of them are galvanically insulated by means of optocouplers from the outside world.

The electrical characteristics of these inputs are:

Nominal voltage +24 V DC.Maximum voltage +30 V.Minimum voltage +18 V.High input threshold (logic state 1) above +18 VLow input threshold (logic state 0) below + 5 V.Typical consumption per input 5 mA.Maximum consumption per input 7 mA.

All the inputs are protected by:

Galvanic insulation by means of optocouplers.Against reversed connection of the power supply up to -30 V DC.

Atencin:

The external 24 V DC power supply being used to feed the digital inputs andoutputs must be regulated.

The 0V point of that power supply must be connected to the main ground pointof the electrical cabinet.

DIGITAL I/O


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5MACHINE AND POWER INTERFACE

2.2.4 ANALOG OUTPUTS.

There are several analog outputs to control the drives for the axes and for the spindle.

The electrical characteristics of these outputs are:

Analog voltage range 10V DC.Minimum impedance of the connected drive 10 KOhm.Maximum unshielded cable length 75 mm.

It is recommended to use shielded cable and connecting the shield to the correspondingconnector pin.

Atention:

It is also recommended to adjust the axes drives in such a way that the desiredmaximum feedrate (P110, P111, P310, P311) corresponds to an analog voltageof 9.5 V DC.

2.2.5 FEEDBACK INPUTS

These inputs are used to receive sine-wave as well as single-ended and double-ended(differential) square-wave signals supplied by linear (scales) and rotary transducers (encoders).

Connector A1 is used for X axis feedback connection and accepts both single ended sine-wave and differential square-wave signals.

Connector A3 is used for Z axis feedback connection and accepts both single ended sine-

wave and differential square-wave signals.

Connector A4 is used for the second handwheel feedback connection (for the Z axis) andit accepts both single ended sine-wave and differential square-wave signals.

Connector A5 is used for spindle feedback connection and accepts differential square-wavesignals.

Connector A6 is used for the first handwheel feedback connection (for the X axis only whenhaving two handwheels) and it accepts only single-ended square-wave signals (notdifferential).

The electrical characteristics of these inputs are:

Sine-wave signals

Power supply voltage 5V.5%Maximum counting frequency 25KHz.

Square-wave signals

Power supply voltage 5V.5%Maximum counting frequency 200KHz.

It is recommended to use shielded cable and connecting the shield to the correspondingconnector pin.

ANALOG OUTPUTSFEEDBACK INPUTS


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2.3 SET-UP

2.3.1 GENERAL CONSIDERATIONS

Inspect the whole electrical cabinet verifying the ground connections BEFORE poweringit.

This ground connection must be done at a single machine point (Main Ground Point) andall other ground points must be connected to this point.

Verify that the 24V power supply used for the digital inputs and outputs of the PLC isREGULATED and that its 0V are connected to the Main Ground Point.

Verify the connection of the feedback system cables to the CNC.

DO NOT connect or disconnect these cables to/from the CNC when the CNC is on.

Look for short-circuits in all connectors (inputs, outputs, axes, feedback, etc.) BEFOREsupplying power to them.

2.3.2 PRECAUTIONS

It is recommended to reduce the axis travel installing the limit switches closer to each otheror detaching the motor from the axis until they are under control.

Verify that there is no power going from the servo drives to the motors.

Verify that the connectors for the digital inputs and outputs are disconnected.

Verify that the dip-switches for each feedback device are set properly according to the typeof feedback signals being used.

Verify that the E-STOP button is pressed.

SET-UP


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2.3.3 CONNECTION

Verify that the A.C. power is correct.

Being the CNC disconnected, power the electrical cabinet and verify that it respondsproperly.

Verify that there is proper voltage between the pins corresponding to 0V and 24V of theconnectors for the digital inputs and outputs.

Apply 24V to each one of the terminals of the electrical cabinet being used that correspondto the digital outputs of the CNC and verify their correct performance.

With the motors being decoupled from the axes, verify that the system consisting of drive,motor and tach is operating properly.

Connect the A.C. power to the CNC. If there is any problem, the CNC will display thecorresponding error; otherwise it will display the message: GENERAL TEST PASSED.

SET-UP


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2.3.4 SYSTEM I/O TEST

This CNC offers a particular operating mode where it is possible to activate and deactivatethe logic inputs and outputs of the CNC.

To access this mode, press the following keystroke sequence:

[AUX] (SPECIAL FUNCTIONS)[5] (AUXILIARY MODES)[0] [1] [0] [1] (Password)[1] (SPECIAL MODES)[0] (TEST)

Once the CNC's self-test is done, press [7], the CNC will display the status of the logic inputsand outputs; and it will allow changing the status of the logic outputs.

Logic inputs

INPUT PIN FUNCTION

A 17 (I/O 1) STARTB 16 (I/O 1) STOPC 15 (I/O 1) FEED-HOLDD 14 (I/O 1) EMERGENCY STOPE 13 (I/O 1) Not being used at this timeF 12 (I/O 1) Z axis home switch (Io)G 11 (I/O 1) Not being used at this timeH 10 (I/O 1) X axis home switch (Io)I 19 (I/O 1) MANUAL (DRO mode)J 18 (I/O 1) Not being used at this timeK To be used only by the Service DepartmentL To be used only by the Service DepartmentM To be used only by the Service DepartmentN To be used only by the Service Department

The CNC will show dynamically and at all times the status of all these inputs. To checkany of them, act upon the external switches and observe the status change of thecorresponding input on the screen.

The status of "1" indicates that the corresponding input is receiving 24V DC. If not, itwill appear as "0".

SET-UP


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Logic outputs

1ST ROW 2ND ROWOUTPUT PIN/FUNCTION PIN/FUNCTION

A (2 I/O 1) T Strobe (3 I/O 2) Output 1, decoded MB (3 I/O 1) S Strobe (4 I/O 2) Output 2, decoded MC (4 I/O 1) M Strobe (5 I/O 2) Output 3, decoded MD (5 I/O 1) Emergency (6 I/O 2) Output 4, decoded ME (6 I/O 1) CYCLE ON (7 I/O 2) Output 5, decoded MF (7 I/O 1) Z Enable (8 I/O 2) Output 6, decoded MG (8 I/O 1) Reset (9 I/O 2) Output 7, decoded MH (9 I/O 1) X Enable (10 I/O 2) Output 8, decoded MI (27 I/O 1) MST01 (11 I/O 2) Output 9, decoded MJ (26 I/O 1) MST02 (12 I/O 2) Output 10, decoded MK (25 I/O 1) MST04 (13 I/O 2) Output 11, decoded M

L (24 I/O 1) MST08 (25 I/O 2) Output 12, decoded MM (23 I/O 1) MST10 (24 I/O 2) Output 13, decoded MN (22 I/O 1) MST20 (23 I/O 2) Output 14, decoded MO (21 I/O 1) MST40 (22 I/O 2) Output 15, decoded MP (20 I/O 1) MST80 (21 I/O 2) CNC Work mode

To check the outputs, select them by means of the up and down arrow keys.

Once the desired output is selected, turn it on (1) or off (0) by assigning to it itscorresponding value.

It is possible to have several outputs activated at the same time and all of them willprovide 24V DC at their corresponding pin when active.

Once the I/O test is completed, disconnect the electrical cabinet and, then, connect the I/Oconnectors as well as those of the feedback devices to the CNC.

Afterwards, connect the electrical cabinet and the CNC to AC power and activate the servodrives.

To quit the system I/O test mode, press [END].

SET-UP


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2.4 EMERGENCY INPUT/OUTPUT CONNECTION

The Emergency Input of the CNC is called EMERGENCY STOP (E-STOP) andcorresponds to pin 14 of connector I/O1. This input must normally have 24V DC.

The CNC processes this signal directly, therefore, whenever these 24V disappear, it willissue EXTERNAL EMERGENCY ERROR (error 64), it will deactivate the axes enablesand cancel the analog voltages to all the axes and the spindle.It does NOT imply the emergency output.

The electrical cabinet interface must take into account all the external elements that couldcause this error.

For example, some of these elements may be:

* The E-Stop button has been pressed.

* An axis travel limit switch has been pressed.

* An axis servo drive is not ready.

On the other hand, whenever a CNC detects an internal emergency error, it will activatethe EMERGENCY OUTPUT at pin 5 of connector I/O 1.

Th

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Fagor 800T Manual